System and method for mounting electrical devices

ABSTRACT

In one embodiment an electronic device, such as an optical sensor, is attached to a substrate upon which wire logouts and, if desired, other components are constructed. A frame, or cover, is attached to the substrate surrounding the attached device. An aperture in the cover allows wireless signals to pass in or out of the cover.

TECHNICAL FIELD

This invention relates to mounting of electrical devices.

BACKGROUND OF THE INVENTION

Currently, optical navigation devices are constructed using an insert-molded lead frame based package. The insert-molded package is constructed by molding a plastic package over a metal-based lead frame. An optical sensor (or die) is attached to the lead frame inside the plastic package. An electronic component, such as wire bonds, provide the electrical connections from the die to the leads (pins) of the lead frame, and hence to the outside world. This construction is relatively expensive and requires a metal stamping tool as well as a molding tool to achieve the finished product. In addition, the spacing between traces (the metal runs on the lead frame) is controlled by lead frame stamping capabilities.

BRIEF SUMMARY OF THE INVENTION

In one embodiment an electronic device, such as an optical sensor, is attached to a substrate upon which wire logouts and, if desired, other components are constructed. A frame, or cover, is attached to the substrate surrounding the attached device. An aperture in the cover allows wireless signals to pass in or out of the cover.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows one example of prior art of an optic sensor using insert-molded lead frame packaging;

FIG. 1B shows a side view of the sensor of FIG. 1A;

FIG. 1C shows a sectional view of the sensor of FIG. 1A;

FIG. 1D shows one example of prior art unmolded lead frames;

FIG. 2A shows one embodiment of an optical sensor mounted on a substrate;

FIG. 2B shows a bottom view of the device of FIG. 2A;

FIG. 2C shows a sectional view taken along line 2-2 of the device of FIG. 2A;

FIGS. 3A and 3B show alternative embodiments of an optical sensor mounted on a substrate; and

FIGS. 4 and 5 show other alternative embodiments of sensors mounted on substrates.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1A shows one example of prior art optical sensor device 10 using an insert-molded lead frame based package 16 having cover 11 thereon. The insert-molded package is constructed by molding a plastic package over a metal based lead frame, such as one of the frames 16 shown in FIG. 1D. Sensor 15 is attached inside the molded package as shown in FIG. 1C. Wire bonds provide the electrical connections from sensor 15 to contacts 12 and hence to the outside world.

FIG. 1B shows a side view of device 10. Such a device is inherently large and requires a stamping tool to cut the lead frame and a molding tool to form the package over the lead frame. A mechanical tool is also required to trim and bend or form the lead into the proper dimensions. The final product is not only labor intensive, but bulky.

FIG. 1C shows a sectional view of device 10 and illustrates how signals, such as light signals, pass through orifice 14 to impact on device 15. Cover 11 is fitted to protect device 10.

FIG. 1D shows one embodiment of a number of lead frames in their bare (unmolded) slate. An optical device could be attached to pad 120.

FIG. 2A shows one embodiment of device 20 having an electronic device, such as optical sensor (or die) 25 (shown in FIG. 2C) mounted on substrate 21. Substrate 21 is formed and processed having suitable features for attaching the die wires (and other components, if desired) such that the sensor can be electrically connected to the other elements contained on the substrate and also connected to terminals 22 which connect the substrate of the outside world. Sensor 15 can operate in the visual spectrum or in any spetrum.

FIG. 2B shows a bottom view of device 20 where housing 200 covers optical sensor 25. Aperture 24 is formed in dome 26 so as to allow wireless signals, such as light, to enter or exit housing 200.

FIG. 2C shows a sectional view of device 20 taken along lines 2-2 of FIG. 2A showing sensor 25 contained within housing 200. Housing 200 is attached to substrate 21 via openings 202 (shown in FIG. 2A) with tabs 201 of housing 200 being pushed through the openings in a one-way direction. Housing 200 could contain stiffening braces 203, if desired, to provide rigidity of the housing with respect to substrate 21. Wire bonding can be utilized to electrically connect sensor 25 to respective traces on substrate 21. Note that sensor 25 could be a sensor for receiving wireless signals from outside device 20, or could be a transmitter for sending such signals, or could be both. The signals are communicated, either inbound or outbound, via aperture 24. In one embodiment, the signals are optic signals and aperture 24 is transparent to such optic signals while blocking unwanted signals or wavelengths. While not shown, a cover could be positioned with respect to aperture 24 to keep out unwanted material, or signals, but still be transparent to the desired signals.

Electrically conductive pins 22 may be attached prior to or after attaching the sensor and/or wire bonds and the pins may extend from the same side of the substrate as the sensor, or from the reverse side, or from both sides. Sensor 25 and housing 200 in this embodiment are fitted so as to fall between parallel rows of terminals. Housing 200 is attached after sensor 25 is added to protect the sensor and wire bonds. Housing 200 contains suitably sized and shaped opening 24 which acts as an optical aperture. Note that sensor 15 is not limited to an optic sensor but rather can be any device positioned such so as to receive or transmit signals via an aperture. While the aperture shown in this embodiment is in-line with the sensor it could be off-set therefrom if desired.

Housing 200 can be attached to substrate 21 by chemical bonding, adhesive, welding, heat sealing, or a combination thereof. In addition, if desired, housing 200 can be sealed using an opaque sealing agent to limit stray light and/or particles from leaking into the package at the interface with the substrate. The total height of the device, including housing 200, is less than the normal height of terminals 22, which is approximately 4.2 mm. However, any size will work.

FIG. 3A shows one alternative device 30 having housing 200 (with a sensor inside) mounted on substrate 31 upon which flat (planar) terminals 32L are positioned.

FIG. 3B shows a top view of device 30 with flat (planar) terminals 32U showing that the terminals that connect to the outside world can be on the bottom (32L), or top (32U), or on both surfaces as desired. Housing 200 is snapped into substrate 31 using tabs 201 through holes 202 in substrate 31.

FIG. 4 shows an alternative embodiment where device 40 has optics, such as lens 45, positioned in housing 200. Optics 45 can be active or passive and serves to modify or direct wireless signals passing there through. The optics could be a filter to block certain signals and, if desired, could be used to block dust and other particles from entering housing 200, as well as to pass the desired signals.

FIG. 5 shows another embodiment 50 where instead of having perpendicular terminals 22, substrate 31 has planar contacts as shown in FIGS. 3A and 3B. Note that while housing 200 is shown being mechanically attached to the substrate by a latch mechanism it could also be attached, as discussed above, using chemical bonding, adhesive, welding, heat staking or a combination thereof.

Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. 

1. A method for constructing an electrical device, said method comprising the steps of: attaching, both physically and electrically, an electrical device to a substrate; and mounting a housing to said substrate such that said housing surrounds said attached electrical device, said housing having at least one aperture therein allowing wireless signals to pass through said aperture to impact said electronic device.
 2. The method of claim 1 wherein said electronic device is an optical device.
 3. The method of claim 2 wherein said optical device operates in the visual spectrum.
 4. The method of claim 1 wherein said wireless signals passing through said aperture move across an open space prior to impacting said electrical device.
 5. The method of claim 1 further comprising the step of: optically sealing the edges of said housing where said edges contact said substrate.
 6. The method of claim 1 wherein said mounting comprises using a quick connect mechanism.
 7. The method of claim 6 wherein said quick connect mechanism is selected from the list of: one-way snap latches, glue, chemical bonding, heat bonding, rivets, welding, screws.
 8. The method of claim 1 wherein said housing is a unitary structure with an aperture open to the passage of said signals.
 9. The method of claim 8 wherein said unitary structure is constructed from one of the following: metal, plastic, polymer.
 10. The method of claim 1 further comprising: the step of: positioning an optical element within said housing, said optical element positioned between said aperture and said electrical device.
 11. A housing comprising: a body for surrounding an electrical device mounted on a substrate; means for attachment of said body to said substrate; and an aperture in said body for allowing wireless signals to pass through said aperture to impact an electronic device mounted on said substrate.
 12. The housing of claim 11 further comprising: an optical element positioned within said body.
 13. The housing of claim 12 wherein said optical element is positioned in said aperture such that wireless signals passing through said aperture are modified by said optical element.
 14. The housing of claim 13 wherein said optical element comprises a lens.
 15. The housing of claim 11 further comprising: at least one stiffening member positioned within said body, said stiffening member having a portion for contacting said substrate.
 16. The housing of claim 11 wherein said electrical device comprises an optical sensor.
 17. The housing of claim 11 wherein said attachment means comprises a latch for mating with a slot in said substrate.
 18. An optical device comprising: means for attaching an electrical device to a substrate; and means for completely enclosing an attached optical device using a unitary preconstructed housing having at least one aperture therein, said aperture allowing wireless signals to pass through said aperture to impact upon said enclosed electronic device.
 19. The optical device of claim 18 wherein said enclosing means comprises: a quick connect mechanism for mounting said housing to said substrate.
 20. The optical device of claim 19 wherein said quick connect mechanism is selected from the list of: one-way snap latches, glue, chemical bonding, heat bonding, rivets, welding, screws.
 21. The optical device of claim 19 wherein said housing, when mounted to said substrate, has a form factor less than 4.2 mm.
 22. The optical device of claim 19 wherein said electronic device is an optical sensor.
 23. The optical device of claim 20 wherein said optical sensor operates in the visual light spectrum.
 24. The optical device of claim 19 wherein said aperture is in-line with said enclosed electrical device.
 25. The optical device of claim 19 further comprising: an optical element positioned within said housing between said aperture and said electronic device.
 26. The optical device of claim 19 wherein said substrate has a plurality of terminals for electrically connecting said electronic device to external devices, said plurality of terminals positioned at the periphery of said substrate; and wherein both said electronic device and said housing are positioned in an area within said terminals. 